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November 18, 2020 NHTSA CAMPAIGN NUMBER: 20V714000

A rear brake disc fracture may result in a reduction of braking performance, increasing the risk of a crash.

NHTSA Campaign Number: 20V714

Manufacturer Chrysler (FCA US LLC)

Components SERVICE BRAKES, HYDRAULIC

Potential Number of Units Affected 8

Summary

Chrysler (FCA US LLC) is recalling certain 2020 Alfa Romeo Giulia vehicles. The rear brake discs may fracture during vehicle operation.

Remedy

FCA US LLC will notify owners, and dealers will replace the rear brake discs and pads, free of charge. The recall began December 17, 2020. Owners may contact FCA US LLC customer service at 1-800-853-1403. FCA US LLC’s number for this recall is W86.

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

Check if your Vehicle has a Recall

Revision (1) March 2021

Dealer Service Instructions for:

Safety Recall W86 / NHTSA 20V-714 Rear Brake Discs

NOTE: Additional information added to “Parts Return” section on Page 3.

Remedy Available

2020

(GA)

Alfa Romeo Giulia

NOTE: This recall applies only to the above vehicles equipped with Carbon Ceramic Material (CCM) rear brake discs.

NOTE: Some vehicles above may have been identified as not involved in this recall and therefore have been excluded from this recall.

IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process.

Subject

The rear brake discs on about 8 of the above vehicles may fracture. A rear brake disc fracture during vehicle operation may result in reduced braking performance, which can cause a vehicle crash without prior warning.

Repair

Replace the rear brake discs and brake pads.

Alternate Transportation

Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if the vehicle must be held overnight.

Parts Information

Part Number	Qty.	Description
68416484AA	1	Rear brake pad and disc kit (4 pads and 2 discs)
68300207AA	4	Parking brake caliper fastening screw (MSQ 4)
06106188AA	2	Cable tie (MSQ 10)

Parts Return

Using DHL parcel service, provide the Brembo customer number 958130361 to send back the recalled brake discs so that shipping can be charged directly to the supplier without cost to the dealership. Use the packaging from the NEW brake discs to return the recalled brake discs to Brembo.

Send only the removed brake discs, attaching a pro forma invoice containing details of the components being returned and the mileage at which the operation was carried out.

The pro forma invoice must contain the following words:

(For repair free of charge, value for customs purposes only) INCOTERMS 2010 (ICC): DAP CURNO, ITALY

Send the recalled brake discs to the following address:

Brembo S.p.A.
Via Brembo, 25
24035 Curno (Bergamo) – Italy
To the attention of Mr. Claudio Trinceri

IMPORTANT: Failure to return the recalled brake discs will result in the cancellation of the refund claim.

Special Tools

The following special tools are required to perform this repair:

NPN	wiTECH MicroPod II
NPN	Laptop Computer
NPN	wiTECH Software
NPN	Dial Indicator for measuring brake disc eccentricity

Service Procedure

Position the vehicle on a suitable lift.

Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Set the battery charger timer (if so equipped) to continuous charge.

Connect the wiTECH micro pod II to the vehicle data link connector.

Place the ignition in the “RUN” position.

Open the wiTECH 2.0 website.

Enter your “User id” and “Password” and your “Dealer Code”, then select “Sign In” at the bottom of the screen. Click “Accept”.

From the “Vehicle Selection” screen, select the appropriate vehicle.

From the “Action Items” screen, select the “Topology” tab.

Select the “ABS” Icon.

From the “ABS” screen, select the “Miscellaneous Functions” menu and start the “Brembo_® information CCM service reset” procedure for rear disc replacement.

Electrical System Disconnection:

Raise all electrical windows to the upper stop position.

NOTE: Make sure ALL the windows are closed fully. Disconnecting the battery when the windows are in a position other than the upper end stop will entail the need to run the window end stop learning procedure.

Open the luggage compartment lid and support it so it will not close.

CAUTION: While the battery is disconnected, make sure the luggage compartment lid does not close again, as it will not be possible to reopen it.

To be able to reopen the luggage compartment lid, even if it accidentally closes with the battery disconnected, before disconnecting the battery it is necessary to unscrew the cap (1b), release the pull cord hooked onto it and leave it hanging out of the luggage compartment. Then, by working on the pull cord, an emergency luggage compartment lid lock release can be obtained. The pull cord operates on the lever (1a) inside (Figure 1).

Place the ignition in the “OFF” position and then remove the wiTECH micro pod II device and battery charger from the vehicle.

The vehicle must remain powered down for at least 1 minute before taking further action.

Working on the right side of the luggage compartment, turn the retainers (1a) counterclockwise to the end of their travel to release them, then remove the cover (1b) releasing the retainers in the areas (1c) (Figure 2).

Press the release button (1a) and disconnect the negative cable (1b) from the battery post (1c) (Figure 3).

Move the terminal out of the way and isolate it (1b) (Figure 3).

If equipped with an Intelligent Battery Sensor (IBS), disconnect the wire harness connector (2a) from the IBS (1c) (Figure 4).

Rear Brake Pads and Disc Removal for Both Sides of Vehicle:

WARNING: The presence of carbon fiber submerged in a ceramic matrix can produce dust (carbon) that is deposited in the disc pads and surfaces. This dust can cause skin irritation, redness and burns. The technician must use personal protective equipment to protect their health: gloves and mask.

Remove both rear tire and wheel assemblies.

Disconnect the electrical harness connector (1) to the electric parking brake gear motor (Figure 5).

Remove and DISCARD the mounting bolts (2a) and remove the electric parking brake caliper (2b) (Figure 5).

Disconnect the brake pad wear indicator electric harness connection (1) (Figure 6).

Cut the tie strap and release the electrical harness from the support bracket (2) (Figure 6).

Using a suitable punch, retract and remove the pad retaining pins (3) (Figure 6).

Open the cap on the brake fluid reservoir and check the level.

NOTE: The piston retraction operations described here below increase the brake fluid level in the reservoir. Make sure the fluid level does not cause leakage.

Retract the pistons from the brake caliper using a retractor or other suitable tool pressing on the worn pads.

NOTE: Piston retraction must be such so allow extracting the worn pads and then inserting the new ones.

Remove the mounting bolts (1a) and remove the brake caliper (1b) complete with pads, without disconnecting the brake hose (Figure 7).

CAUTION: Securely support the brake caliper so it does not put stress on the brake hose.

Remove the outer brake pad (1) (Figure 8).

Remove the inner brake pad (1) (Figure 9).

NOTE: If the pads are stuck to the pistons, use a spatula or screwdriver and then extract the pads from the caliper. Be careful not to damage the pistons and the dust boots.

Remove and DISCARD the brake caliper retaining clip (1) (Figure 10).

NOTE: The spring must always be replaced.

Carefully clean the pad seat area using suitable materials and products (for example, a moist cloth).

CAUTION: Do not use products which could damage rubber parts, such as thinner, nitro thinner, petrol, etc.

Check that there is no damage to the pistons or the dust boots.

Remove the mounting bolts (1a) and remove the rear brake disc (1b) (Figure 11).

NOTE: Use the packaging from the NEW brake discs to return the recalled brake discs to Brembo. Failure to return the recalled brake discs will result in the cancellation of the refund claim.

Rear Brake Disc and Pads Installation for Both Sides of Vehicle:

Place the NEW rear brake disc (1a) onto the wheel hub and tighten the M10 bolt (1b) to 7 N·m (62 In. Lbs.) (Figure 12).

NOTE: After install the CCM discs, measure the eccentricity of the disc-wheel hub assembly with a dial indicator. An eccentricity of more than 0.10 mm is not acceptable.

NOTE: If the eccentricity is greater than 0.10 mm, rotate the disc to another position (there are 5 available positions) to achieve the smallest eccentricity possible.

NOTE: The eccentricity must be measured 10 mm from the disc’s outer edge, on the braking side. The correct eccentricity value is vital for stabilizing braking. If the eccentricity values are too high, it will result in abnormal wear and strong vibrations.

Install some “MOLYKOTE Cu7439 Plus” grease to the brake pad sliding shoulders and a NEW brake caliper retaining spring in its housing (Figure 13).

Install the NEW inner brake pad (2) in its housing, complete with wear sensor (2) (Figure 14).

NOTE: The arrow printed on the brake pad must be oriented in the direction of rotation of the disc when travelling forwards.

Install the NEW outer brake pad (1) in its housing (Figure 15).

NOTE: The arrow printed on the brake pad must be oriented in the direction of rotation of the disc when travelling forwards.

Install the brake pad retaining pins (1) (Figure 16).

Position the brake caliper (1a) in its housing and set the brake pad retaining pins (1b) (Figure 17).

Install the brake caliper M12 mounting bolts (2) and tighten the bolts to 105 N·m (77 Ft. Lbs.) (Figure 17).

Connect the electrical harness connector to the pad wear sensor (3a), secure it to the bracket with a NEW cable tie (3b) (Figure 17).

Pump brake pedal several times to set pads to caliper and brake rotor.

Check that the brake fluid in the reservoir is at the maximum level, otherwise top off using the recommended fluid.

Securely tighten the brake fluid reservoir cap on the brake fluid reservoir.

NOTE: The fluid in the reservoir should not exceed the MAX notch.

Position the electric parking brake caliper (1a) in its housing and tighten the NEW M10 mounting bolts (1b) to 30 N·m + 45 degrees (22 Ft. Lbs. + 45 degrees) (Figure 18).

Connect the electrical connection of the gear motor (2) (Figure 18).

Position the rear wheel and tire assembly to the wheel hub and secure it tightening the M14 stud bolts to 120 N·m (89 Ft. Lbs.) (Figure 18).

Electrical System Connection:

Connect the battery negative cable (1b) onto the post (1c) (Figure 19).

If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector (Figure 20).

Position the battery cover (1b) while engaging the retainers (1c), then turn the retainers (1a) clockwise to the end of their travel to secure them (Figure 21).

Close the luggage compartment lid.

Electrical Systems Reset:

Initializing the steering is required. This will be indicated by a warning light on the IPC illuminating. Start the engine, turn the steering wheel from one lock to the other and turn it back into the center position.

Check that the time/day etc. are correct.

Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Set the battery charger timer (if so equipped) to continuous charge.

Connect the wiTECH micro pod II to the vehicle data link connector.

Place the ignition in the “RUN” position.

Open the wiTECH 2.0 website.

Enter your “User id” and “Password” and your “Dealer Code”, then select “Sign In” at the bottom of the screen. Click “Accept”.

From the “Vehicle Selection” screen, select the appropriate vehicle.

From the “Action Items” screen, select the “Topology” tab.

Select the “ABS” Icon.

From the “ABS” screen, select the “Miscellaneous Functions” menu and go to the “Electric Park Brake (EPB)” then perform the “ASSEMBLY CHECK” procedure.

Place the ignition in the “OFF” position and then remove the wiTECH micro pod II device and battery charger from the vehicle.

Remove the vehicle from the lift and return to the customer or inventory.

SEOCONTENT-START

11/19/2020
_____________________________________________________________________
New Safety Recall Advanced Communication – W86
FCA US LLC (FCA US) has announced a safety recall on certain 2020 Model Year (GA) Alfa Romeo Giulia vehicles equipped with Carbon Ceramic Material (CCM) rear brake discs.
REASON FOR THIS SAFETY RECALL
Some of the above vehicles may have been built with rear brake discs that may fracture. A rear brake disc fracture during vehicle operation may result in a dimunition of braking performance, which can cause a vehicle crash without prior warning.
SERVICE ACTION
FCA US will conduct a voluntary safety recall to replace the rear brake discs. The remedy for this condition is not currently available. Dealers will be notified of the launch of this safety recall by way of established communication methods. This recall is estimated to launch in 4th Quarter of 2020.
We ask that you please take the time to ensure that your personnel are aware of this communication and are prepared to execute a customer friendly process for inquiries regarding involved vehicles.
Customer Services Field Operations
FCA US LLC

****************************************************************************************************************

11/25/2020
_____________________________________________________________________
New Safety Recall Advanced Communication – W86
FCA US LLC (FCA US) has announced a safety recall on certain 2020 Model Year (GA) Alfa Romeo Giulia vehicles equipped with Carbon Ceramic Material (CCM) rear brake discs.
VINs identified as being involved in this campaign are currently live and searchable. Stop sale is in effect for the above-identified vehicles.
Vehicles impacted by a stop sale are eligible for reimbursement allowance through the Recall Floorplan Reimbursement Policy (RFPRP), which can be requested upon recall claim submission.
REASON FOR THIS SAFETY RECALL
Some of the above vehicles may have been built with rear brake discs that may fracture. A rear brake disc fracture during vehicle operation may result in a dimunition of braking performance, which can cause a vehicle crash without prior warning.
SERVICE ACTION
FCA US will conduct a voluntary safety recall to replace the rear brake discs. The remedy for this condition is not currently available. Dealers will be notified of the launch of this safety recall by way of established communication methods. This recall is estimated to launch in 4th Quarter of 2020.
We ask that you please take the time to ensure that your personnel are aware of this communication and are prepared to execute a customer friendly process for inquiries regarding involved vehicles.
Customer Services Field Operations
FCA US LLC
IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Violation of this requirement by a dealer could result in a civil penalty of up to $21,000 per vehicle. Involved vehicles can be determined by using the VIP inquiry process.

****************************************************************************************************************

Safety Recall W86 – Rear Brake Discs Page 17
Claims for vehicles that have been serviced must be submitted on the
DealerCONNECT Claim Entry Screen located on the Service tab. Claims paid
will be used by FCA to record recall service completions and provide dealer
payments.
Use the following labor operation numbers and time allowances:
Labor Operation Time
Number Allowance
Replace Rear Brake Discs and Brake Pads 05-W8-61-82 1.0 hour
Related
Handling Charge for Return of 95-21-42-50
Brake Discs to Brembo
Add the cost of the recall parts package plus applicable dealer allowance to your
claim.
NOTE: See the Warranty Administration Manual, Recall Claim Processing
Section, for complete recall claim processing instructions.
To view this notification on DealerCONNECT, select “Global Recall System” on
the Service tab, then click on the description of this notification.
All involved vehicle owners known to FCA are being notified of the service
requirement by first class mail. They are requested to schedule appointments for this
service with their dealers. A generic copy of the owner letter is attached.
Completion Reporting and Reimbursement
Dealer Notification
Owner Notification and Service Scheduling
Safety Recall W86 – Rear Brake Discs Page 18
All involved vehicles have been entered into the DealerCONNECT Global Recall
System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed.
GRS provides involved dealers with an updated VIN list of their incomplete
vehicles. The owner’s name, address and phone number are listed if known.
Completed vehicles are removed from GRS within several days of repair claim
submission.
To use this system, click on the “Service” tab and then click on “Global Recall
System.” Your dealer’s VIN list for each recall displayed can be sorted by: those
vehicles that were unsold at recall launch, those with a phone number, city, zip
code, or VIN sequence.
Dealers must perform this repair on all unsold vehicles before retail delivery.
Dealers should also use the VIN list to follow up with all owners to schedule
appointments for this repair.
Recall VIN lists may contain confidential, restricted owner name and address information that
was obtained from the Department of Motor Vehicles of various states. Use of this information
is permitted for this recall only and is strictly prohibited from all other use.
If you have any questions or need assistance in completing this action, please
contact your Service and Parts District Manager.
Customer Services / Field Operations
FCA US LLC
Vehicle Lists, Global Recall System, VIP and Dealer Follow Up
Additional Information
This notice applies to your vehicle,
W86/NHTSA 20V-714
YOUR SCHEDULING OPTIONS
1. RECOMMENDED OPTION
Call your authorized Alfa Romeo
dealership.
2. Call Alfa Romeo Premium Care at
1-866-932-3881. An agent can
confirm part availability and help
schedule an appointment.
3. Visit recalls.mopar.com, scan the
QR code below, or download the
Mopar Owner’s Companion App.
Get access to recall notifications, locate
your FIAT Studio, and more through
this website or Mopar Owner’s
Companion App. You will be asked to
provide your Vehicle Identification
Number (VIN) to protect and verify
your identity. The last eight characters
of your VIN are provided above.
DEALERSHIP INSTRUCTIONS
Please reference Safety Recall W86.
IMPORTANT SAFETY RECALL
Rear Brake Discs
Dear [Name],
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
FCA has decided that a defect, which relates to motor vehicle safety, exists in certain [2020
(GA) Alfa Romeo Giulia] vehicles equipped with Carbon Ceramic Material (CCM) rear brake
discs.
It is extremely important to take steps now to repair your vehicle to ensure the safety of you and
your passengers.
WHY DOES MY VEHICLE NEED REPAIRS?
The rear brake discs on your vehicle [1] may fracture. A rear brake disc fracture during
vehicle operation may result in reduced braking performance, which can cause a
vehicle crash without prior warning.
HOW DO I RESOLVE THIS IMPORTANT SAFETY ISSUE?
FCA will repair your vehicle [2] free of charge (parts and labor). To do this, your dealer
will replace the rear brake discs. The estimated repair time is one hour. In addition, your dealer
will require your vehicle for proper check-in, preparation, and check-out during your visit,
which require more time. Your time is important to us, so we recommend that you schedule a
service appointment to minimize your inconvenience. Please bring this letter with you to your
dealership.
TO SCHEDULE YOUR FREE REPAIR,
CALL YOUR ALFA ROMEO DEALER TODAY
WHAT IF I ALREADY PAID TO HAVE THIS REPAIR COMPLETED?
If you have already experienced this specific condition and have paid to have it repaired, you
may visit www.fcarecallreimbursement.com to submit your reimbursement request online. [3]
Once we receive and verify the required documents, reimbursement will be sent to you within
60 days. If you have had previous repairs performed and/or already received reimbursement,
you may still need to have the recall repair performed.
We apologize for any inconvenience, but are sincerely concerned about your safety. Thank you
for your attention to this important matter.
Customer Assistance/Field Operations
Fiat Chrysler Automobiles US LLC
[Model Year and Model]
VIN XXXXXXXXXXXXXXXXX
LOGO
VEHICLE PICTURE
QR Code
Mr. Mrs. Customer
1234 Main Street
Hometown, MI 48371
[1] If you no longer own this vehicle, please help us update our records. Call Alfa Romeo Premium Care at 1-866-932-3881 to update your information.
[2] If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway
Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC 20590, or you can call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-
9153), or go to safercar.gov.
[3] You can also mail in your original receipts and proof of payment to the following address for reimbursement consideration: FCA Customer Assistance, P.O. Box 21-8004,
Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement.
Note to lessors receiving this recall notice: Federal regulation requires that you forward this recall notice to the lessee within 10 days

****************************************************************************************************************

SEOCONTENT-END

1 Affected Product

Vehicle


MAKE	MODEL	YEAR
ALFA ROMEO	GIULIA	2020

12 Associated Documents

Manufacturer Notices(to Dealers,etc) – Media Release re FCA US LLC (FCA US) has announced a safety recall on certain 2020 Model Year (GA) Alfa Romeo Giulia vehicles equipped with Carbon Ceramic Material (CCM) rear brake discs.

RCMN-20V714-3982.pdf 100.588KB

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Recall Quarterly Report #1, 2020-4

RCLQRT-20V714-8485.PDF 211.128KB

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Remedy Instructions and TSB – Rear Brake Discs

RCRIT-20V714-8398.pdf 1535.627KB

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Owner Notification Letter(Part 577)

RCONL-20V714-9430.pdf 514.792KB

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Remedy Instructions and TSB

RCRIT-20V714-5277.pdf 1455.523KB

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Recall Quarterly Report #2, 2021-1

RCLQRT-20V714-1145.PDF 211.23KB

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ISSUED Renotification Notice

RCRN-20V714-9961.pdf 138.314KB

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Recall Acknowledgement

RCAK-20V714-5926.pdf 244.756KB

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RCMN-20V714-5014.pdf 97.249KB

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Defect Notice 573 Report

RCLRPT-20V714-6615.PDF 213.853KB

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Recall Quarterly Report #3, 2021-2

RCLQRT-20V714-5838.PDF 211.311KB

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Recall Quarterly Report #4, 2021-3

RCLQRT-20V714-4232.PDF 211.414KB

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V714&docType=RCL

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STURDY HANDLES: The 4 brake spring tools feature reinforced ergonomic handles to save you time and spare you effort and aggravation during use
CUSTOM CASE: The rugged blow-molded case of this rear drum brake tool kit keeps everything well organized and easy to store or transport between jobs
SATISFACTION GUARANTEED: Orion Motor Tech backs this drum brake tool set with our usual strong warranty and friendly 24/7 customer service, ensuring that you'll enjoy its use for years to come!

SaleBestseller No. 8

Lisle 25750 Dual Piston Brake Caliper Compressor, metal

Compresses Dual Brake Pistons Simultaneously.
Squeeze the tool handle until the plunger contacts the inboard brake pad.
Continue squeezing to compress both pistons.
Makes dual piston pad replacement a simple job.
Patent: 7,076,850

Bestseller No. 9

MAKOTOOLS Aain MKT30 Professional Drum Brake Tool Set with Spring Removal Tool, Brake Retaining Spring Tool, Brake Spring Pliers, 8pcs

Set Includes, Spring Compressor, Brake Spring Installer, Spring Removal Tool, Brake Retaining Spring Tool, Brake Spring Pliers, Two Brake Adjustment Spoons Mini Adjustment Spoon
Made of chrome plated, heat-treated metal, for strength and longevity. Durable, molded, and textured, safe grip handles are designed to reduced user fatigue.
Heavy duty blow molded plastic carrying case is easy to transport, simple to store, and quick to organize.
Spring installers, disconnectors, and holding tools help safely adjust the brake spring deep into your braking system, while a variety of adjustment spoons help you adjust the clearance between drum brakes and brake shoes; 8 Brake Lining Thickness Gauges help you identify thickness levels and know when to replace your gaskets.
8 Piece Set with portable drum brake disassembly kit. Suitable for most domestic and international cars and trucks

SaleBestseller No. 10

Lang Tools 279-5420 279 Brake Caliper Press

Works on twin and quad piston fixed calipers, as well as single and twin piston floating calipers
Centrally located ratchet evenly spreads force in a parallel manner to prevent misalignment of pistons
Ratchet technology gives a full 360 degree swing so that the spreader may be placed at any position
Extended reversing lever allows for easy change from spreading to retracting
Made in the USA

Last update on 2024-04-21 / Affiliate links / Images from Amazon Product Advertising API

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Safety Recall W86 – Rear Brake Disc – 2020 Alfa Romeo Giulia

Summary

Remedy

Notes

Safety Recall W86 / NHTSA 20V-714 Rear Brake Discs

Remedy Available

Subject

Repair

Alternate Transportation

Parts Information

Parts Return

Special Tools

Service Procedure

Latest Recalls Documents

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